Cutter head for shield machine and shield construction method

Abstract

A cutter head for a shield machine and a shield construction method. In the shield construction method, force sensors measure the pressure borne by hobs (103), so as to determine, on the basis of pressure signals, the hardness of rock being processed currently, when the pressure signals reach or exceed a preset value, a controller is started to control microwave rock breaking systems (104) to heat the rock being processed currently, and the specific mode is to provide, on the basis of the pressure signals and a reference signal, a quantitative determination mode for whether the microwave rock breaking systems (104) need to be started, such that the control is more convenient, and energy is saved. Furthermore, the physical characteristics of the rock are changed, so that cracks appear in the rock, thereby reducing the rock strength, and reducing the abrasion of a shield machine cutter. By prolonging the service life of cutters and shortening the shutdown maintenance and cutter replacement time, the construction efficiency is improved, and the construction duration is shortened.

Description

Shield cutter head for shield machine and shield construction method Technical Field

[0001] The present invention relates to the field of shield equipment, and in particular to a shield cutterhead for a shield machine and a shield construction method. Background Art

[0002] The cutterhead is a key component of a shield machine, its primary function being to crush and strip the rock and soil at the tunnel face, as well as to support the tunnel face. Existing shield machine cutterheads crush rock during construction by squeezing and colliding the cutters on the cutterhead. However, this process also causes rapid wear of the cutters, which necessitates machine downtime for inspection and replacement. This replacement process is complex and time-consuming, and frequent cutter replacement significantly impacts construction progress, significantly reducing the efficiency of continuous construction operations.

[0003] The prior art provides a new shield machine (CN107605497A) capable of detecting and directionally removing obstacles. The shield machine of this invention is equipped with a radar transmitter to detect and locate obstacles. A microwave transmitter protection box with an open top is installed on the back of the shield machine's cutterhead. The microwave transmitter protection box houses an electric turntable, on which a microwave transmitter is fixed. The microwave transmitter rotates with the electric turntable. The number of microwave transmitter protection boxes is the same as the number of cutterhead cutters. The present invention has a simple structure and is easy to implement. Combining radar detection and positioning functions, it accurately locates large rocks or other obstacles that are difficult for the cutterhead to break ahead of the shield machine during tunneling. Then, by controlling the direction of the microwave transmitter fixed to the middle of the cutterhead cutter back, microwaves are emitted in a directionally directed manner toward the obstacle, thereby removing the obstacle and ensuring timely emergency preparedness. This effectively predicts and handles obstacles using the shield machine itself. However, this method is ineffective when there is a large amount of hard rock mass.

[0004] The prior art also provides a drilling and tunneling equipment and method (CN113790060B), which includes: a cutterhead cutting system, a heating system, and a cooling system; the cutterhead cutting system includes a cutterhead panel, a cutting tool, a main drive shaft, and a drive shaft drive mechanism; the cutting tool is arranged on the cutterhead panel and is used to cut the rock mass, one end of the main drive shaft is connected to the drive mechanism, and the other end is connected to the cutterhead panel, so that the drive shaft drive mechanism can drive the cutterhead to rotate via the active drive shaft; the heating system is arranged on the cutterhead panel and is used to microwave heat the rock mass; the cooling system is arranged on the cutterhead panel and is used to water mist cool the rock mass. The present invention applies microwave and water mist synergistically assisted rock breaking technology to field projects of geological drilling and tunneling, improving the efficiency of deep hard rock drilling and excavation, and reducing the wear of shield machine tools when cutting and shearing rock mass. In the above method, the microwave water mist is always in the on state during operation, which has high energy consumption.

[0005] Summary of the Invention

[0006] The purpose of the present invention is to provide a shield cutterhead for a shield machine and a shield construction method, aiming to solve the problems existing in existing shield construction, such as severe shield cutter wear, long downtime for cutter replacement, high tool costs, long construction period and low overall construction efficiency.

[0007] To achieve the above-mentioned objectives, the present invention provides a shield cutterhead for a shield machine and a shield construction method, comprising a cutterhead body, a scraper, a roller cutter, a microwave rock breaking system, and a controller. The roller cutter is equipped with a force sensor, which is arranged on the cutterhead body. The force sensor is used to detect a pressure signal applied to the roller cutter. The scraper is arranged on one side of the roller cutter. The controller is connected to the force sensor and the microwave rock breaking system. The controller is used to control the microwave rock breaking system based on the pressure signal, so that cracks appear in the rock under the action of microwaves. The controller comprises a data acquisition module, a judgment module, and a drive module, which are sequentially connected.

[0008] The data acquisition module is used to acquire a pressure signal, the judgment module is used to calculate a ratio of the pressure signal to a reference signal, and the driving module is used to drive the microwave rock breaking system to operate based on the ratio.

[0009] The microwave rock breaking system includes a microwave emission source, a microwave transmission antenna, a wave-transmitting protective plate, and a microwave power supply. There are multiple microwave rock breaking systems, and the multiple microwave rock breaking systems are distributed in the radial direction of the cutterhead.

[0010] There are multiple force sensors, and the multiple force sensors are distributed on one side of the multiple microwave rock breaking systems.

[0011] Among them, the data acquisition module includes a first numbering unit, a second numbering unit and a mapping unit. The first numbering unit is used to number multiple force sensors to obtain a sensor number group. The second numbering unit is used to number multiple microwave rock breaking systems to obtain a microwave rock breaking number group. The mapping unit is used to establish a mapping relationship between the sensor number group and the microwave rock breaking number group.

[0012] Among them, the driving module includes a level generation unit, a matching unit and a driving unit. The level generation unit is used to generate a driving level based on a historical ratio range. The matching unit is used to match the real-time ratio of the corresponding number with the driving level to obtain an actual driving level. The driving unit is used to drive the microwave rock breaking system of the corresponding number to operate based on the actual driving level.

[0013] Wherein, the controller also includes a prediction module, which is used to generate a predicted driving level based on historical ratios; the prediction module includes a historical ratio data acquisition unit, an analysis unit, a prediction unit and a correction unit, the historical ratio data acquisition unit is used to acquire ratio data within a past time period, the analysis unit is used to calculate the average value of the ratio data, the prediction unit is used to generate a predicted driving level based on the average value, and the correction unit is used to correct the predicted driving level based on the real-time ratio.

[0014] In a second aspect, the present invention further provides a shield construction method, comprising:

[0015] Start the shield machine and the cutterhead begins to rotate and start construction;

[0016] During the construction process, when the shield machine advances to the rock area, the controller detects that the pressure signal reaches the preset value and sends a control signal;

[0017] The controller turns on the microwave rock breaking system based on the control signal, causing cracks to appear inside the rock.

[0018] In the construction process, when the shield machine advances to the rock area, the controller detects that the pressure signal reaches a preset value, and the specific steps of sending the control signal include: obtaining the pressure signal,

[0019] Calculating the ratio of the pressure signal to the reference signal;

[0020] The microwave rock breaking system is driven to operate based on the ratio.

[0021] The specific steps of driving the microwave rock breaking system to operate based on the ratio include:

[0022] Generate drive levels based on historical ratio ranges,

[0023] Match the real-time ratio of the corresponding number with the drive level;

[0024] The microwave rock breaking system with the corresponding number is driven to operate based on the actual driving level.

[0025] In a third aspect, the present invention further provides a shield machine comprising the shield cutterhead.

[0026] The present invention provides a shield cutterhead and shield construction method for a shield machine. The cutterhead body supports all structures, while the scraper scrapes the crushed rock and the roller cutter crushes the rock. During operation, a force sensor detects the pressure applied to the roller cutter, allowing the hardness of the rock being processed to be determined based on the pressure signal. When the pressure signal reaches or exceeds a preset value, the controller activates the microwave rock breaking system to heat the rock being processed. Specifically, a quantitative determination is made based on the pressure signal and a reference signal to determine whether the microwave rock breaking system should be activated, making control more convenient and saving energy. This in turn changes the rock's physical properties, causing cracks to form within the rock, thereby reducing rock strength and reducing wear on the shield machine's cutters. This increases cutter life, reduces downtime for maintenance and cutter changes, improves construction efficiency, and shortens construction periods. This method addresses existing shield construction issues such as severe cutter wear, long cutter change downtime, high cutter costs, long construction periods, and low overall efficiency. Furthermore, the present invention activates the microwave rock breaking system based on the pressure signal, saving energy. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0028] FIG1 is a structural diagram of a shield cutterhead for a shield machine according to a first embodiment of the present invention.

[0029] FIG2 is a structural diagram of a controller according to a second embodiment of the present invention.

[0030] FIG3 is a structural diagram of a data acquisition module according to a second embodiment of the present invention.

[0031] FIG. 4 is a structural diagram of a driving module according to a second embodiment of the present invention.

[0032] FIG5 is a structural diagram of a prediction module according to a second embodiment of the present invention.

[0033] FIG6 is a flow chart of a shield construction method according to the third embodiment of the present invention.

[0034] 7 is a flow chart showing a process in which, during the construction of the third embodiment of the present invention, after the shield machine advances to the rock area, the controller detects that the pressure signal reaches a preset value and issues a control signal.

[0035] FIG8 is a flow chart of the controller according to the third embodiment of the present invention, which starts the microwave rock breaking system 104 based on the control signal, so as to generate cracks inside the rock.

[0036] The cutter head body 101, the scraper 102, the roller cutter 103, the microwave rock breaking system 104, the data acquisition module 201, the judgment module 202, the drive module 203, the first numbering unit 204, the second numbering unit 205, the mapping unit 206, the level generation unit 207, the matching unit 208, the drive unit 209, the historical ratio data acquisition unit 211, the analysis unit 212, the prediction unit 213, and the correction unit 214. DETAILED DESCRIPTION

[0037] The following describes embodiments of the present invention in detail, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and are not to be construed as limiting the present invention.

[0038] First embodiment

[0039] Referring to FIG. 1 , the present invention provides a shield cutterhead for a shield machine, comprising a cutterhead body 101, a scraper 102, a roller cutter 103, a microwave rock breaking system 104, and a controller. The roller cutter 103 is equipped with a force sensor, disposed on the cutterhead body 101, for detecting a pressure signal applied to the roller cutter 103. The scraper 102 is disposed on one side of the roller cutter 103. The controller is connected to the force sensor and the microwave rock breaking system 104. The controller is configured to control the microwave rock breaking system 104 based on the pressure signal, thereby causing cracks to form within the rock under the action of microwaves. The controller comprises a data acquisition module 201, a judgment module 202, and a drive module 203, which are sequentially connected. The data acquisition module 201 is configured to acquire a pressure signal, the judgment module 202 is configured to calculate a ratio of the pressure signal to a reference signal, and the drive module 203 is configured to drive the microwave rock breaking system 104 based on the ratio.

[0040] In this embodiment, the cutterhead body 101 supports all structures, while the scraper 102 scrapes the crushed rock, and the roller cutter 103 crushes the rock. During operation, the force sensor detects the pressure applied to the roller cutter 103, allowing the hardness of the rock being processed to be determined based on the pressure signal. When the pressure signal reaches or exceeds a preset value, the controller activates the microwave rock breaking system 104 to heat the rock being processed. Specifically, a quantitative determination is made based on the pressure signal and a reference signal as to whether the microwave rock breaking system should be activated, making control more convenient and saving energy. This in turn changes the rock's physical properties, causing cracks to form within the rock, thereby reducing rock strength and reducing wear on the shield machine's cutters. This increases cutter life, reduces downtime for maintenance, and reduces cutter changes, thereby improving construction efficiency and shortening the construction period. This solves the problems existing in existing shield construction, such as severe shield tool wear, long downtime for tool change, high tool cost, long construction period, and low overall construction efficiency. At the same time, the present invention starts the microwave rock breaking system 104 according to the pressure signal according to the situation, thereby saving energy.

[0041] Second embodiment

[0042] Please refer to Figures 2 to 5. Figure 2 is a block diagram of a controller according to a second embodiment of the present invention. Figure 3 is a block diagram of a data acquisition module according to a second embodiment of the present invention. Figure 4 is a block diagram of a driver module according to a second embodiment of the present invention. Figure 5 is a block diagram of a prediction module according to a second embodiment of the present invention.

[0043] Based on the first embodiment, the present invention further provides a shield cutterhead for a shield machine. The microwave rock-breaking system 104 includes a microwave emission source, a microwave transmission antenna, a wave-transmitting protective plate, and a microwave power supply. Multiple microwave rock-breaking systems 104 are provided, and are distributed radially along the cutterhead. Multiple microwave rock-breaking systems 104 can heat corresponding rock regions, thereby improving energy utilization.

[0044] There are multiple force sensors, and the multiple force sensors are distributed on one side of the multiple microwave rock breaking systems 104. Through the force sensors, the rock strength of the corresponding area can be detected, so that the operation of the microwave rock breaking system 104 in the corresponding area can be more conveniently controlled.

[0045] The data acquisition module 201 includes a first numbering unit 204, a second numbering unit 205, and a mapping unit 206. The first numbering unit 204 is used to number multiple force sensors to obtain sensor number groups. The second numbering unit 205 is used to number multiple microwave rock breaking systems 104 to obtain microwave rock breaking number groups. The mapping unit 206 is used to establish a mapping relationship between sensor number groups and microwave rock breaking number groups. This method can be used to match force sensors with microwave rock breaking systems 104, making signal-based control more convenient.

[0046] The driving module 203 includes a level generation unit 207, a matching unit 208, and a driving unit 209. The level generation unit 207 is used to generate a driving level based on a historical ratio range. The matching unit 208 is used to match the corresponding number's real-time ratio with the driving level to obtain an actual driving level. The driving unit 209 is used to drive the corresponding numbered microwave rock breaking system 104 to operate based on the actual driving level. To prevent the microwave rock breaking system 104 from being unable to process the rock into the desired state after operation, the present application divides the operating power of the microwave rock breaking system 104 into multiple levels, allowing operation based on different levels for greater convenience.

[0047] The controller also includes a prediction module for generating a predicted drive level based on historical ratios. The prediction module includes a historical ratio data acquisition unit 211, an analysis unit 212, a prediction unit 213, and a correction unit 214. The historical ratio data acquisition unit 211 is used to acquire ratio data from a past time period, the analysis unit 212 is used to calculate an average value of the ratio data, the prediction unit 213 is used to generate a predicted drive level based on the average value, and the correction unit 214 is used to correct the predicted drive level based on the real-time ratio. If real-time data is used entirely for control, the scraper and roller cutter will be subjected to a large impact before being crushed, which will also cause damage to the scraper and roller cutter. However, the properties of the rock formation are continuous. The present application can stabilize the drive level within a certain range based on historical ratio data and make corrections using real-time data, thereby further reducing wear.

[0048] Third embodiment

[0049] Please refer to Figures 6 to 8. Figure 6 is a flow chart of a shield construction method according to the third embodiment of the present invention. Figure 7 is a flow chart of the construction process according to the third embodiment of the present invention, in which the controller detects that the pressure signal reaches a preset value and issues a control signal after the shield machine advances into the rock area. Figure 8 is a flow chart of the controller activating the microwave rock breaking system 104 based on the control signal, causing cracks to form within the rock, according to the third embodiment of the present invention.

[0050] On the basis of the second embodiment, the present invention further provides a shield construction method, comprising:

[0051] S101 starts the shield machine and the cutterhead begins rotating;

[0052] During the S102 construction process, when the shield machine advances to the rock area, the controller detects that the pressure signal reaches the preset value and sends a control signal;

[0053] The specific steps include:

[0054] S201 obtains the pressure signal,

[0055] S202 calculates the ratio of the pressure signal to the reference signal;

[0056] S203 drives the microwave rock breaking system 104 to operate based on the ratio.

[0057] Through the above-mentioned method, the microwave rock breaking system 104 can be conveniently controlled according to the pressure signal.

[0058] S103 The controller starts the microwave rock breaking system 104 based on the control signal, causing cracks to appear inside the rock.

[0059] The specific steps include:

[0060] S301 generates a driving level based on a historical ratio range;

[0061] S302 matches the real-time ratio of the corresponding number with the drive level;

[0062] S303 drives the microwave rock breaking system 104 with the corresponding number to operate based on the actual driving level.

[0063] Fourth embodiment

[0064] On the basis of the first embodiment, the present invention further provides a shield machine including the shield cutterhead.

[0065] The above disclosure is only a preferred embodiment of the present invention, and certainly cannot be used to limit the scope of the rights of the present invention. Ordinary technicians in this field can understand that all or part of the processes of the above embodiment and equivalent changes made in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A shield cutterhead for a shield machine, comprising a cutterhead body, a scraper and a roller cutter, characterized in that: It also includes a microwave rock breaking system and a controller, wherein the roller cutter is equipped with a force sensor, the roller cutter is arranged on the cutter head body, and the force sensor is used to detect the pressure signal received by the roller cutter; the scraper is arranged on one side of the roller cutter, and the controller is connected with the force sensor and the microwave rock breaking system, and the controller is used to control the microwave rock breaking system based on the pressure signal so that cracks appear inside the rock under the action of microwaves, and the controller includes a data acquisition module, a judgment module and a driving module, and the data acquisition module, the judgment module and the driving module are connected in sequence; The data acquisition module is used to acquire the pressure signal, the judgment module is used to calculate the ratio of the pressure signal to the reference signal, and the driving module is used to drive the microwave rock breaking system to operate based on the ratio.

2. A shield cutterhead for a shield machine as claimed in claim 1, characterized in that: The microwave rock breaking system includes a microwave emission source, a microwave transmission antenna, a wave-transmitting protective plate, and a microwave power supply. There are multiple microwave rock breaking systems, and the multiple microwave rock breaking systems are distributed in the radial direction of the cutter head.

3. A shield cutterhead for a shield machine as claimed in claim 2, characterized in that: There are multiple force sensors, and the multiple force sensors are distributed on one side of the multiple microwave rock breaking systems.

4. A shield cutterhead for a shield machine as claimed in claim 3, characterized in that: The data acquisition module includes a first numbering unit, a second numbering unit and a mapping unit. The first numbering unit is used to number multiple force sensors to obtain a sensor number group; the second numbering unit is used to number multiple microwave rock breaking systems to obtain a microwave rock breaking number group; the mapping unit is used to establish a mapping relationship between the sensor number group and the microwave rock breaking number group.

5. A shield cutterhead for a shield machine as claimed in claim 4, characterized in that: The driving module includes a level generating unit, a matching unit and a driving unit. The level generating unit is used to generate a driving level based on a historical ratio range. The matching unit is used to match the real-time ratio of the corresponding number with the driving level to obtain an actual driving level. The driving unit is used to drive the microwave rock breaking system of the corresponding number to operate based on the actual driving level.

6. A shield cutterhead for a shield machine as claimed in claim 5, characterized in that: The controller also includes a prediction module, which is used to generate a prediction drive dynamic level; the prediction module includes a historical ratio data acquisition unit, an analysis unit, a prediction unit and a correction unit, the historical ratio data acquisition unit is used to obtain the ratio data in the past time period, the analysis unit is used to calculate the average value of the ratio data, the prediction unit is used to generate a predicted driving level based on the average value, and the correction unit is used to correct the predicted driving level based on the real-time ratio.

7. A shield construction method, using the shield cutterhead according to claim 1, characterized in that: include: Start the shield machine and the cutterhead starts to rotate for construction; During the construction process, when the shield machine advances to the rock area, the controller detects that the pressure signal reaches the preset value and sends a control signal; The controller turns on the microwave rock breaking system based on the control signal, causing cracks to appear inside the rock.

8. A shield construction method as claimed in claim 7, characterized in that: During the construction process, when the shield machine advances to the rock area, the controller detects that the pressure signal reaches a preset value, and the specific steps of sending a control signal include: Obtain pressure signal; Calculate the ratio of the pressure signal to the reference signal; The microwave rock breaking system is driven to operate based on the ratio.

9. A shield construction method as claimed in claim 8, characterized in that: The specific steps of driving the microwave rock breaking system to operate based on the ratio include: Generate drive levels based on historical ratio ranges; Match the real-time ratio of the corresponding number with the drive level; The microwave rock breaking system with the corresponding number is driven to operate based on the actual driving level.

10. A shield machine, characterized in that: It comprises the shield cutter head as described in any one of claims 1 to 6.

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